Rotork MOD Series Modules — MOD 6G Main PCB

Technical Dossier

Product Details And Specifications

Rotork MOD Series: Comprehensive Module Range and Technical Overview

The Rotork MOD Series represents one of the most widely deployed actuator control and monitoring module families in global heavy industry. Installed across petrochemical complexes, nuclear power stations, offshore platforms, and crude oil refineries, MOD Series modules serve as the primary interface layer between field-mounted electric actuators and plant-level DCS/SCADA systems. The series is engineered to IEC 60068 environmental standards and is rated for continuous operation in Class I hazardous area installations. Its modular backplane architecture allows hot-swap replacement of individual function cards without full system shutdown — a critical requirement in continuous-process industries where unplanned downtime carries six-figure hourly cost penalties. The MOD platform is recognized by major EPC contractors (Bechtel, Technip, Wood Group) as a preferred actuator interface standard, with installed base spanning over 40 countries.

The Evolution of MOD Series Architecture

The Rotork MOD Series was introduced as a successor to the earlier A-Range and IQ-Range standalone control modules, consolidating distributed actuator intelligence into a rack-mounted, bus-addressable format. Early-generation MOD hardware (MOD 1x, MOD 2x) used parallel wiring topologies and proprietary RS-485 derivatives for inter-module communication. The MOD 3x generation introduced HART protocol compatibility, enabling integration with asset management platforms such as Emerson AMS and Honeywell FSC. The MOD 5x and MOD 6x generations represent the current mature architecture, incorporating dual-redundant power rails, CAN bus backplane communication, and optional Profibus DP / Modbus RTU field network adapters. Compatibility between generations requires careful attention: MOD 6x CPU cards are not backward-compatible with MOD 3x backplanes without a firmware bridge adapter. As of 2024, Rotork has formally classified MOD 1x and MOD 2x hardware as End-of-Life (EOL), with MOD 3x entering the Mature/Sustained phase. MOD 5x and MOD 6x remain in active production. For plants operating legacy MOD 2x or MOD 3x infrastructure, third-party lifecycle extension suppliers such as DriveKNMS provide tested replacement boards and cross-reference mapping to current equivalents.

MOD Series Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly sourced components within the Rotork MOD Series. Each module is classified by functional category.

CPU / Controller Modules

• MOD 6G: Main PCB assembly for MOD 6x generation; primary logic controller with dual CAN bus interface and onboard diagnostics.
• MOD 5G: Main PCB for MOD 5x generation; supports Modbus RTU and HART pass-through; predecessor to MOD 6G.
• MOD 3G: CPU card for MOD 3x generation; RS-485 master controller; classified Mature/EOL-approaching.
• MOD 6G-CPU: Standalone CPU daughterboard for MOD 6G; field-replaceable without full PCB swap.

Digital Input (DI) Modules

• MOD 6DI-8: 8-channel 24 VDC digital input module; IEC 61131-2 Type 1 compliant; used for limit switch and torque switch feedback.
• MOD 6DI-16: 16-channel digital input expansion; supports sink/source wiring; standard in large valve manifold applications.
• MOD 5DI-8: 8-channel DI for MOD 5x backplane; 120 VAC input rated; common in North American refinery installations.
• MOD 3DI-8: Legacy 8-channel DI; 24 VDC; requires MOD 3x backplane; EOL hardware.

Digital Output (DO) Modules

• MOD 6DO-8: 8-channel relay output module; 2A per channel; used for open/close actuator command signals.
• MOD 6DO-16: 16-channel transistor output; 0.5A per channel; high-density valve control applications.
• MOD 5DO-8: 8-channel relay DO for MOD 5x; 250 VAC rated contacts; common in motor control center (MCC) interfaces.

Analog Input / Output (AI/AO) Modules

• MOD 6AI-8: 8-channel 4–20 mA analog input; 16-bit resolution; used for valve position feedback and torque monitoring.
• MOD 6AO-4: 4-channel 4–20 mA analog output; used for modulating actuator setpoint commands.
• MOD 5AI-8: 8-channel AI for MOD 5x; HART-enabled on all channels; compatible with Emerson DeltaV asset management.

Communication / Network Adapter Modules

• MOD 6-PB: Profibus DP V1 communication adapter for MOD 6x; supports up to 244 bytes I/O; GSD file available.
• MOD 6-MB: Modbus RTU/TCP gateway module for MOD 6x; configurable baud rate 9600–115200.
• MOD 5-PB: Profibus DP adapter for MOD 5x backplane; legacy integration with Siemens S7 and ABB 800xA systems.

Power Supply Modules

• MOD 6-PSU: 24 VDC / 10A redundant power supply module for MOD 6x rack; hot-swap capable.
• MOD 5-PSU: 24 VDC / 6A power supply for MOD 5x; single-rail; non-redundant configuration.

Sourcing Hard-to-Find & Obsolete MOD Series Parts

Quality Control for the MOD Series Range

MOD Series modules present specific test challenges due to their multi-layer backplane bus architecture and mixed analog/digital signal paths. DriveKNMS applies the following verification protocol to all MOD Series units prior to dispatch: (1) Visual inspection for PCB delamination, capacitor bulge, and connector pin corrosion — common failure modes in units recovered from high-humidity or coastal installations. (2) Powered functional test on a dedicated MOD-compatible test rack, verifying backplane CAN bus communication, I/O channel continuity, and LED status indication. (3) For CPU modules (MOD 6G, MOD 5G, MOD 3G): firmware version verification and EEPROM integrity check. (4) For analog modules: calibration verification against a traceable 4–20 mA reference source, with channel-by-channel linearity confirmation. (5) Burn-in cycle: 48-hour continuous operation at 40°C ambient to screen for early-life failures. All test results are documented and shipped with each unit. Units that fail any stage of the protocol are quarantined and not offered for sale.